Forum AM in Construction Engineering & Architecture


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09:00 - 09:05

Welcome from the Rapid.Tech 3D Live-TV-Studio

Michael Kynast, Michael Eichmann und Prof. Gerd Witt | Messe Erfurt GmbH, Stratasys GmbH, Universität Duisburg-Essen

Michael Kynast, CEO Messe Erfurt GmbH
Michael Eichmann, Stratasys GmbH, Advisory Board Rapid.Tech 3D
Prof. Gerd Witt, Universität Duisburg-Essen, Lehrstuhl Fertigungstechnik, Advisory Board Rapid.Tech 3D

09:05 - 09:15

Welcome from the Rapid.Tech 3D Live-TV-Studio

Valentina Kerst | State Secretary Thuringian Ministry for Economy, Science and Digital Society
09:15 - 09:45

The aerospace industry is characterized by small quantities, the highest safety requirements and, more than almost any other industry, by the need to save weight. Every reduced kilogram of weight saves up to 3 kg of CO2 - and that on a daily basis. Moreover, the short-term supply of spare parts is quite challenging. That is why aerospace industry is ideal for the introduction of components that are topologically optimized and manufactured by 3D printing processes. For more than 10 years, parts have been converted from conventional design and manufacturing to additive processes. The results are clear: components become lighter, smaller and may even integrate more functions.

Nevertheless, the conversion process is progressing slowly. There are several reasons, starting first and foremost with the demand for maximum safety. With existing design and production processes, all necessary qualifications are available for the required safety of components. For 3D printing, unfortunately, we are still at the beginning and, therefore, invest a lot of time and energy in process qualifications. We have to ensure that the internal structures and the surfaces meet all the requirements for permanent, safe operations. In parallel, we are, of course, continuing to work on optimizing the processes, on new material combinations and design processes, because we are certain that 3D printing will be indispensable for the climate-neutral aircraft of the future.

Volker Thum | BDLI Bundesverband der Deutschen Luft- und Raumfahrtindustrie e.V.

Volker Thum

09:45 - 09:50
Greetings from the Rapid.Tech 3D Live-TV-Studio
09:50 - 10:00
Break & Chat Roulette
10:00 - 14:00
Live-Stream: Forum "AM Science II"
14:00 - 14:15
Coffee break & Chat Roulette
14:15 - 14:45

Additive manufacturing in construction is a rapidly growing field of research and development on the threshold to practical application. Numerous solutions have been presented involving a large range of materials in various processes. However, even though the use of wood in such processes would open up the chance to employ a renewable raw material and to reduce material costs, examples of this approach are scarce. In this paper the general possibilities to use wood in additive manufacturing are outlined. Processes, designed with a view to large scale and applications in construction are presented and finally selected solutions, like the extrusion of lightweight concrete or the selective binding of wood based bulk material, are discussed in more detail.

Klaudius Henke | Technische Universität München

Klaudius Henke

14:45 - 15:15

This paper shows the advantages, disadvantages and potentials of the additive manufacturing process "Selective Laser Melting" (SLM) using a specific example from construction industry.
It describes quality challenges in terms of process monitoring, component testing and properties, process stability and reproducibility.
These observations are made from the perspective of OTTO FUCHS KG, a company that has been active in metal forming for over 100 years and uses forging, extrusion and ring rolling to manufacture components from light metals for the automotive, aerospace and construction industry.
Together with Schüco International KG, a subsidiary of OTTO FUCHS KG, individual components for the construction industry are to be provided fast, flexibly and resource-efficiently.
AM standards and processes created in the surroundings of aerospace industry form a solid basis for the presented project.
After a brief introduction, the example shows the AM-compatible process design. Characteristic results of the printed components are compared with those of the conventionally manufactured component.
In addition to various component properties, process quality, analyses accompanying the print job, as well as reproducibility, are particularly considered in order to pave the way for a component that can be approved.
The paper concludes with a summary and an outlook on further potential.

Sebastian Künne | OTTO FUCHS KG

Sebastian Künne

15:15 - 15:45

Current conventional construction methods contribute to a significant amount of total waste, which has major negative financial and environmental impacts. Additive manufacturing (AM) offers faster, safer, cost-effective, and environmentally sustainable construction systems as a future alternative to the current conventional methods. Furthermore, the potential application of AM in construction has expanded significantly in recent years but has been limited to small scale prototypes. The recent development of computational form-finding and AM has broadened the opportunity for extensive exploration into the design of highly-efficient structural systems. The presented research  investigates the potential to which topology optimization and AM can be used to extend the boundaries of the design of high-performance construction systems. This process builds up material only in areas of high stress based on biomimetic principles found in nature, maximizing structural performance while minimizing weight. The proposed robotically controlled additive manufacturing and computational design platform will revolutionize the construction industry by developing new processes to design and fabricate full-scale high-performance 3D - printed building components. The results of the new proposed technology will be the first step toward a novel, fully integrated robotic fabrication approach to construction driven by the material economy of net-zero carbon smart building components.

Maged Guerguis | The University of Tennessee

Maged Guerguis

15:45 - 16:15

The so-called Selective Cement Activation, SCA technology for short, combines additive (series) production with construction in a radically new way.

With this (extraordinary) technology it is possible to combine aspects such as sustainability, industrialization and the advantages of freedom of geometry in construction.

Additive Tectonics GmbH, founded in 2020 as a daughter company of FIT AG, is fully committed to the application, research and further development of this new technology.

With a view to sustainability, it is examining a manufacturing concept of zero-waste production, with a focus on the entire life cycle of a construction product (component). Starting with the resource-saving use of raw materials, material mix, production, post-processing up to the recycling of produced components and return to the manufacturing process (circular system).

For this purpose, the properties and advantages of a newly developed material Econit, a magnesium oxychloride cement, are compared with Portland cement, which is widely used in construction. Sustainability is examined not only on the basis of the energy balance, but also through sustainable functional integration, e.g. through heat, fire, noise protection, lightweight construction and maintenance.

The development of a scalable industrial additive manufacturing system is important to Additive Tectonics GmbH. The focus is on a high degree of automation, industrial quality assurance, freedom of material and geometry and the expansion of production capacity limits.

The lecture gives an insight into the current status of developments and will refute them with some application examples.

Christian Wiesner | Additive Tectonics GmbH

Christian Wiesner

16:15 - 16:30
Coffee break and Chat Roulette
16:30 - 17:00

The Presentation highlights opportunities and challenges of incorporating AM technology on the Boeing 777X Folding Wingtip System Secondary Lock Actuator.

The Case Study shows how Liebherr addressed challenges like thermal stresses in production, pressure drops in operation, surface treatment and wear surfaces of titanium cylinders.
Furthermore, an outlook will be provided regarding the challenges of the technology and the implementation to serial production of highly integrated components.

Alexander Altmann | Liebherr-Aerospace Lindenberg GmbH
17:00 - 17:05
Farewell to the Rapid.Tech 3D Live-TV-Studio